Pressure sensor monolithically integrated and relative process of fabrication

ABSTRACT

Abstract of the Disclosure A monolithically integrated pressure sensor is produced through micromechanical surface structure definition techniques. A microphone cavity in the semiconductor substrate may be monolithically formed by plasma etching the front side or the back side of the silicon wafer to cut a plurality of trenches or holes deep enough to extend for at least part of its thickness into a doped buried layer of opposite type of conductivity of the substrate and of the epitaxial layer grown over it. The method may also include electrochemically etching through such trenches, the silicon of the buried layer with an electrolytic solution suitable for selectively etching the doped silicon of the opposite type of conductivity, thereby making the silicon of the buried layer porous. The method may also include oxidizing and leaching away the silicon so made porous.

FIELD OF THE INVENTION

[0001] The present invention relates in general to pressure sensors, and, in particular, to an integrated pressure sensor and a related process of fabrication using surface micromachining.

BACKGROUND OF THE INVENTION

[0002] Pressure sensors are used in several applications, particularly in processes of active noise cancellation, and especially in distributed parameter systems, such as an airplane cabin or the interior of a vehicle. Semiconductor pressure sensors are widely used for these purposes. Their sensing element is a vibrating silicon diaphragm topped by a spaced backplate layer provided with a plurality of openings and formed of polycrystalline silicon (polysilicon or briefly “poly”), both disposed over a microphone cavity.

[0003] These pressure sensors are constructed starting from a semiconductor structure obtained by defining the area of the pressure sensor and implanting a dopant to form a doped layer of a certain type in a monocrystalline silicon substrate of doping type opposite to that of the doped layer that is finally created as a doped buried layer upon growing an epitaxial layer of the same type of doping of the substrate thereon. The epitaxial layer in the area of the sensor will eventually become the diaphragm of the sensor.

[0004] By etching from the substrate, that is etching the substrate from the back side thereof to reach the buried doped layer, the latter is uncovered and thereafter selectively etched to leave a microphone diaphragm provided by the epitaxial layer overhanging a so-realized cavity (microphone cavity). This known technique requires that the mask or masks used to carry out the etchings on the back side of the substrate must be perfectly aligned with the masks that are normally used on the front side of the semiconductor wafer for realizing a suitable backplate structure of the pressure sensor above the diaphragm.

[0005] This is an unavoidable drawback because of the special equipment that is needed, the relative poor precision of alignment that can be achieved, and the relative high costs. Moreover, the selective chemical etching of the buried doped silicon layer is typically carried out at a relatively high temperature (in the range of 85-90° C.), typically using an aqueous solution of potassium hydroxide KOH, to achieve a sufficiently fast etching rate.

[0006] A further drawback of the known process is that the etching rate (microns of material removed per minute) in a direction normal to the plane of the substrate is typically 0.3 μm/min, while the speed of the etching in a direction parallel to the plane of the substrate is about 0.03 μm/min, that is ten times smaller. This produces a typically V-shaped groove 12, as depicted in FIG. 1. The V-shaped groove 12 is formed in the silicon substrate 11 using the masking layer 15 to form the membrane area 13 of the membrane layer 14 over the groove.

[0007] Such a V-shaped cross section of the microphone cavity may be observed in known semiconductor microphones of different kind, such as those depicted in FIGS. 2a-2 d, whether they are piezoresistive (FIG. 2a), piezoelectric (FIG. 2b), capacitive (FIG. 2c) or optically read (FIG. 2d). This represents a tolerated, but far from optimal, shape because of the non-uniformity of pressure wave reactions over the microphone sensing area.

[0008] The rear of the microphone cavity is successively closed by the so called “wafer bonding” technique. In other words, the sensor is bonded onto a flat silicon wafer, in which the associated circuitry may be integrated.

[0009] A method for realizing integrated CMOS structures by first realizing portions of circuits on a separate wafer and thereafter carrying out a wafer bonding, is described in the U.S. Pat. No. 5,659,195. In practice, the above described known process, which is relatively complicated by the wafer bonding step, does not provide for a monolithically integratable pressure sensor. Moreover, it is not possible to vary the depth of the microphone cavity that is predetermined by the thickness of the substrate.

SUMMARY OF THE INVENTION

[0010] It has been found and is the object of the invention a process for realizing pressure sensors monolithically integratable together with a semiconductor integrated circuit on the same chip, and which overcomes the above mentioned limits and drawbacks of prior art techniques.

[0011] According to the present invention, monolithically integrated pressure sensors of outstanding quality and versatility are produced through micromechanical surface structure definition techniques typical of MEMS (MicroElectroMechanical Systems). More precisely, the object of the invention is a process of fabrication of a pressure sensor that may comprise forming in a monocrystalline silicon substrate of a certain type of conductivity a buried layer of opposite type of conductivity upon growing an epitaxial layer of the same type of conductivity of the substrate. The method may also include forming a sacrificial layer of oxide over the epitaxial layer, forming a polysilicon backplate layer with a plurality of holes above the area of the sensor on the sacrifical oxide layer, and chemically etching the sacrifical oxide layer through the holes of the polysilicon backplate layer thereby removing the sacrificial oxide in the sensor area. In addition, the method may include forming a microphone cavity in the sensor area under the epitaxial layer diaphragm by selectively etching the doped silicon of the buried layer.

[0012] Differently from the known processes, according to this invention a microphone cavity in the semiconductor substrate may be monolithically formed by carrying out the following steps before forming the sacrifical oxide layer:

[0013] 1) cutting by plasma etching the front side or the back side of the silicon wafer to form a plurality of trenches or holes deep enough to extend for at least part of its thickness into the buried layer to be selectively etched;

[0014] 2) electrochemically etching through such trenches the silicon of the buried layer with an electrolytic solution suitable for selectively etching the doped silicon of the opposite type of conductivity, thereby making the silicon of the buried layer porous; and

[0015] 3) oxidizing and leaching away the silicon so made porous.

[0016] Narrow trenches or holes, reaching into the buried layer are realized in the first step, while in the second step the silicon of the buried layer is rendered highly porous. The so made porous silicon may be then easily oxidized and a final chemical etching of the oxidized silicon may be carried out at significantly lower temperatures than those that are normally required by prior art techniques based on the selective etching of the doped monocrystalline silicon. The trenches or holes for accessing the doped buried layer may even be cut through the epitaxial layer and not through the rear of the monocrystalline silicon substrate. This may avoid the burden of precisely aligning the mask on the rear surface with the masks that are used on the front surface of the substrate. Moreover, the thickness of the substrate is normally greater than that of the epitaxial layer. Thus, the need to cut relatively deep and narrow trenches requiring the use of special plasma etching equipment may be avoided.

[0017] Optionally, the porous silicon of the buried layer may be oxidized immediately after having performed the selective electrochemical etching or it may be oxidized later in the process, after having deposited the polysilicon layer of backplate.

[0018] A further advantage of the present invention is to provide pressure sensors with a cavity that may be wholly defined in a monolithic semiconducting substrate and whose shape and dimensions may be freely established and with a diaphragm that may be shaped in any desired manner leaving to the designer an unrestrained choice of layout.

[0019] A further advantage of the invention is that of allowing the realization of a monolithically integrated system for detecting the direction of the source of a sound wave, and capable of exploiting to this end an array of integrated pressure sensors of the invention disposed according to a certain layout.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The different aspects and advantages of the invention will become even more evident through a detailed description of an embodiment of the invention and by referring to the attached drawings, wherein:

[0021]FIG. 1 is schematic perspective view of a portion of a monolithic substrate with an integrated diaphragm realized using the known technique of etching the substrate from the back as in the prior art;

[0022]FIGS. 2a-2 d are schematic cross-sectional views of pressure sensors of different types realized by etching the substrate from the back as in the prior art;

[0023]FIGS. 3a-3 h are schematic cross-sectional views illustrating different steps of the process of the invention;

[0024]FIG. 4 is a plan view of an integrated pressure sensor of the invention; and

[0025]FIG. 5 is a schematic circuit diagram of an integrated system for sensing the direction of the source for a sound wave in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] With the process of this invention, the fundamental steps of which are schematically illustrated in FIGS. 3a-3 h, a monolithically integrated pressure sensor is constructed by surface micromachining techniques using a relatively low temperature etching of the doped monocrystalline silicon.

[0027] First, in the defined sensor area, a buried layer 21 of doping of opposite type of conductivity is realized in a doped monocrystalline silicon substrate 20 upon growing thereon of a doped epitaxial layer 22 of the same type of conductivity as the substrate.

[0028] In the example illustrated in FIG. 3a, the buried layer 21 has a P+ doping while the substrate 26 and the epitaxial layer 22 are both N− doped. The invention may be practiced by inverting the types of doping. The buried layer 21 may be 5 to 10 μm thick, and the epitaxial layer 22 may be about 1 μm thick.

[0029] According to the embodiment shown by way of example in FIG. 3b, a plurality of narrow and deep trenches 25 are cut through the epitaxial layer 22 and through part of the thickness of the previously formed buried layer 21 by masking and anisotropically plasma etching. The width of the trenches may be in the range of 3 to 6 μm and the spacing may be 100 μm.

[0030] According to this preferred embodiment, the trenches 25 are cut by plasma etching starting from the front of the wafer thus facilitating mask alignment. The trenches 25 cut from the front of the wafer through the epitaxial layer 22 that will ultimately become the diaphragm of dynamic pressure sensor (pressure wave sensor) should be wide enough to permit electrochemical etching of the silicon of the doped buried layer 21 and the subsequent oxidation of the porous silicon and its chemical leaching away to thereby permit a relief for the air from the microphone cavity when the diaphragm flexes inwardly under the effect of the crest of a pressure wave.

[0031] Overall, the size and distribution of the trenches or holes 25 through the epitaxial layer 22 (diaphragm of the sensor) should desirably be designed, on account of the thickness of the layer, such as to confer on the diaphragm the desired characteristics of flexibility, sturdiness and vibrational modes. In any case, these narrow trenches 25 may be made deep enough to extend for at least a portion of a thickness into the buried layer 21.

[0032] The doped silicon buried layer 21 is selectively etched electrochemically using an electrolytic solution suited to selectively or preferentially dissolve the P+ doped silicon, making the silicon of the buried layer 21 porous as shown in FIG. 3c. Preferably an aqueous solution of hydrofluoric acid (HF) is used.

[0033] Thereafter, the trenches are sealed by depositing a silicon oxide layer by a PVAPOX process and the surface is planarized according to common techniques to produce the structure of FIG. 3c. On the so planarized surface a backplate structure of the sensor is formed according to the known technique of first depositing by a PVAPOX process a layer of sacrificial oxide 26 over the sensor area followed by the deposition of a contouring layer of silicon nitride 27 around the perimeter sacrificial oxide layer (FIG. 3d). Finally, a layer of polycrystalline silicon 28 of the backplate is deposited with a plurality of holes 30 over the sacrificial oxide layer 26 and over the perimetral layer of silicon nitride 27 as shown in FIG. 3e.

[0034] The backplate of polysilicon 28 should be pervious to pressure waves through its plurality of uniformly spaced holes 30 in order to allow a correct action of the pressure wave on the diaphragm provided by the epitaxial layer 22. The backplate should desirably be sufficiently spaced to accommodate an unrestrained maximum deflection of the diaphragm according to the established dynamic range thereof. Normally the gap between the diaphragm and the backplate or grid may be of about 1 μm. Moreover, the polysilicon backplate should have a conductivity sufficient to act as second plate of a capacitor, a first plate of which is provided by the vibrating diaphragm itself.

[0035] According to the embodiment shown, the polysilicon backplate may be n+ doped and may rest on the perimetral isolation layer of silicon nitride 27. Optionally, a second layer of undoped polysilicon may be deposited over the n+ doped layer (conductive plate) for mechanical protection and electrical isolation purposes.

[0036] The layer of sacrifical oxide 26 is then removed by isotropic chemical etching through the holes 30 of the polysilicon backplate layer 28, that will rest on the perimetral supporting layer of silicon nitride 27. Finally, a microphone cavity is realized by chemically etching off the PVAPOX silicon oxide that sealed the trenches as shown in FIG. 3f, and by thermally oxidizing the porous silicon of the buried layer and leaching it away chemically through the re-opened trenches as shown in FIGS. 3g and 3 h.

[0037] Optionally, the porous silicon of the buried layer 21 may be oxidized immediately after having rendered porous by the selective electrochemical etching and continuing the process by sealing the trenches, planarizing the surface and forming the backplate structure of polysilicon.

[0038] Contrary to the sensors of the CMOS device described in the U.S. Pat. No. 5,659,195, wherein the microphone cavity is closed by “wafer bonding” technique, the pressure sensors of this invention are entirely made in a monolithic form. The depth of the microphone cavity of the pressure sensor of this invention may be established simply by varying the thickness of the doped buried layer 21 to be eventually etched away.

[0039] According to the process of the invention, the microphone cavity is realized by dissolving the oxidized porous silicon (that is the oxide). This is a processing step that may be safely performed at room temperature using a diluted solution of hydrofluoric acid. By contrast, the known processes rely on a chemical etching of the monocrystalline silicon of the substrate that must be carried out at a temperature of at least about 85-90° C. because of the unacceptably low rate of the etching at room temperature of monocrystalline silicon.

[0040] The diaphragm of the pressure sensor provided by the epitaxial layer overhanging the microphone cavity formed with the method of this invention may have any shape. For example, it may be in the form of concentric circular sectors, each 100 μm wide, as depicted in FIG. 5.

[0041] The pressure sensor of the invention may be easily integrated using common processing techniques by carrying out a sequence of process steps for selectively making porous the silicon of the doped buried layer, after which common processing steps may follow (for instance according to a standard CMOS process), for realizing the circuitry with which the pressure sensor will interact.

[0042] A further object of the invention is that of providing a monolithically integrated system, as the one depicted in FIG. 6, for sensing the direction of the source of a sound wave and its intensity by analyzing the signals produced by an array of monolithically integrated pressure sensors of the invention, disposed at different locations of the same chip, and using the circuit blocks schematically shown in FIG. 6.

[0043] The distinct pressure sensors of the system, which in the embodiment of FIG. 6 are only two but which may be even more numerous, will produce at different instants an electrical signal representative of the vibration induced on their diaphragm. The direction of the source of a sound wave as sensed by the various pressure sensors of the integrated system of the invention is determined on the basis of the relative delays with which distinct sensors detect the sound wave.

[0044] This may be implemented by carrying out a time-delay correlation between the signal produced by a first sensor and the signal produced by any other sensor present in the integrated device and calculating for which delays the correlations are at their maximum. Each of these delays will represent the difference between the times needed by the sound wave to reach the respective sensor. Knowing the relative positions of the various sensors, it is possible to evaluate by triangulation the direction of the source of the sound wave. 

That which is claimed is:
 1. A process of fabrication of a pressure sensor comprising the steps of forming a buried layer of a second type of conductivity (Si_P+) in a monocrystalline silicon substrate (Si_N−) of a first type of conductivity upon growing an epitaxial layer (N_Si) of said first type of conductivity, depositing a sacrificial oxide layer on said epitaxial layer (N_Si) in the area of said sensor, depositing a polysilicon layer of backplate provided with a plurality of holes over said sacrificial oxide layer isotropically etching said sacrificial oxide layer through said holes as far as removing the oxide in the sensor area and forming a microphone cavity under said epitaxial layer in the sensor area, characterized in that before depositing said sacrifical oxide layer the method comprises the steps of: defining by masking and cutting a plurality of trenches or holes uniformly spaced from one another by anisotropic plasma etching the monocrystalline silicon either from the front side or through the rear side for a depth sufficient to reach through at least a portion of the thickness of said doped buried layer over the area of the sensor; electrochemically etching the doped silicon (Si_P+) of said buried layer through said trenches using an electrolytic solution adapted for selectively dissolving the doped silicon of said opposite kind of conductivity, making the porous the silicon of said buried layer; sealing said trenches or holes by depositing a layer of sealant material; and after having deposited said polysilicon layer of backplate and removed said sacrifical oxide the method comprises the steps of selectively etching said sealant material reopening said trenches or holes; oxidizing the porous silicon of said buried layer and chemically etching the oxidized silicon with an acid solution through the reopened trenches or holes realizing said microphone cavity underneath the epitaxial layer.
 2. The process according to claim 1, wherein said acid solution is a diluted solution of hydrofluoric acid and the etching is carried out at room temperature.
 3. The process according to claim 1, wherein said sealing material and said sacrifical oxide is silicon oxide deposited by a PVAPOX technique.
 4. The process according to claim 1, wherein said cavity and overhanging diaphragm are shaped as concentric circular sectors.
 5. The process according to claim 1, wherein said of oxidation step is carried out immediately after the electrochemical etching of the silicon of the buried layer.
 6. A pressure sensor defined on a monocrystalline silicon substrate and including a microphone cavity a monocrystalline silicon diaphragm closing said cavity and a polycrystalline silicon backplate layer, spaced from said monocrystalline silicon diaphragm and having a plurality of holes overhanging on said diaphragm, characterized in that said pressure sensor is in monolithic form.
 7. The pressure sensor of claim 6, wherein said backplate layer is composed of a first polycrystalline silicon layer with a doping of the same type of conductivity of the substrate and of said epitaxial layer, topped by a second layer of undoped polycrystalline silicon.
 8. A monolithically integrated system for detecting the direction of provenance of a sound wave comprising a plurality of pressure sensors according to anyone of claims 6 and 7, disposed according to a certain layout on the chip and producing respective analog signals; as many analog/digital converters of the signals produced by the respective sensors, generating respectively corresponding digital signals; calculating means performing a time-delay correlation between the digital signal produced by a first sensor and the digital signal of another sensor generating a value of delay for which the correlation is maximum; a microprocessor calculating the direction of provenance of the sound wave as sensed by the pressure sensors in function of said and of said delay values. 